CN111795977A - Online real-time monitoring system of various monitoring equipment for metal additive manufacturing - Google Patents
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Abstract
Description
技术领域technical field
本发明涉及金属增材制造领域,尤其涉及一种金属增材制造多种监测设备在线实时监控系统。The invention relates to the field of metal additive manufacturing, in particular to an online real-time monitoring system for multiple monitoring equipment for metal additive manufacturing.
背景技术Background technique
增材制造被视为未来产业发展的新增长点,在各国政府和市场相互推动下,增材制造技术得到了质的飞跃式发展,但还未形成大规模的工业化应用。在制造过程中成型件的性能和制造精度都会有一定量的不达标,当前SLM产品的成品率大概为70%,较低的成品率严重影响了增材制造大规模工业化应用的进程。其主要原因是加工过程中的工艺可重复性和质量的可靠性问题还没有一种实质可靠的解决方案。目前在航空航天领域,由于器件多是大尺寸构件,耗时大致几天到几个月不等。因此,质量的可靠性尤为重要,亟需实时检测装置或设备对增材制造过程的监测,并进行反馈处理,从而对加工过程进行针对性的调控来实时优化整个加工过程,提高构件最终成品率及打印质量。因此,国内外近几年很多研究机构都对此进行了研究。目前,美国国家航空航天局、美国洛斯阿拉莫斯国家实验室、美国阿贡国家实验室等对大型航空零部件,复杂工业零部件增材制造过程中的加工工件形貌轮廓在线监测进行了研究。德国EOS、德国SLMSolutions、美国3Dsystems公司等对增材制造试样加工材料进行了研究;比利时鲁汶大学、德国亚琛工业大学、芬兰拉彭兰塔理工大学等对增材制造过程熔池尺寸和温度场在线监控、工艺参数反馈控制进行了研究;德国夫琅禾费研究所、西班牙加泰罗尼亚理工大学、美国国家标准与技术研究院等进行了在线和离线超声检测增材类试样内部缺陷研究;清华大学、美国卡内基梅隆大学、英国曼彻斯特大学、澳大利亚蒙纳士大学进行了增材试样缺陷离线X射线检测研究。但是目前,兼顾全方位在线监测并反馈的控制设备还是非常匮乏的,增材制造过程中,工艺参数和外部环境的波动均可能在零件内部局部区域产生各种冶金缺陷,如层间及道间局部未熔合、卷入性和析出性气孔、夹杂物、裂纹、应力集中、翘曲变形等,并最终影响成形零件的内部质量、力学性能和构件的服役使用安全。Additive manufacturing is regarded as a new growth point for future industrial development. Under the mutual promotion of governments and markets, additive manufacturing technology has developed by a qualitative leap, but it has not yet formed a large-scale industrial application. During the manufacturing process, the performance and manufacturing accuracy of the molded parts will be substandard to a certain extent. The current yield of SLM products is about 70%, and the low yield has seriously affected the process of large-scale industrial application of additive manufacturing. The main reason for this is that there is not yet a substantial and reliable solution to the process repeatability and quality reliability issues during processing. At present, in the aerospace field, since the devices are mostly large-sized components, it takes a few days to several months. Therefore, the reliability of quality is particularly important. Real-time detection devices or equipment are urgently needed to monitor the additive manufacturing process and perform feedback processing, so as to conduct targeted regulation of the processing process to optimize the entire processing process in real time and improve the final yield of components. and print quality. Therefore, many research institutions at home and abroad have carried out research on it in recent years. At present, NASA, Los Alamos National Laboratory, Argonne National Laboratory, etc. have carried out research on online monitoring of workpiece morphology and contour in the process of additive manufacturing of large aerospace parts and complex industrial parts. . German EOS, German SLMSolutions, American 3Dsystems, etc. have conducted research on additive manufacturing sample processing materials; Belgian University of Leuven, German RWTH Aachen University, Finland Lappeenranta University of Technology, etc. The online monitoring of temperature field and the feedback control of process parameters were studied; the Fraunhofer Institute in Germany, the Polytechnic University of Catalonia in Spain, and the National Institute of Standards and Technology in the United States conducted online and offline ultrasonic testing of additive samples Internal defect research; Tsinghua University, Carnegie Mellon University in the United States, University of Manchester in the United Kingdom, and Monash University in Australia have conducted offline X-ray inspection of additive sample defects. However, at present, control equipment that takes into account all-round online monitoring and feedback is still very scarce. During the additive manufacturing process, fluctuations in process parameters and external environment may cause various metallurgical defects in local areas inside the part, such as interlayer and inter-passage. Local lack of fusion, entrapment and precipitation pores, inclusions, cracks, stress concentration, warping deformation, etc., and ultimately affect the internal quality, mechanical properties and service safety of the formed parts.
发明内容SUMMARY OF THE INVENTION
本发明的目的在于提供一种金属增材制造多种监测设备在线实时监控系统,旨在用于解决现有的金属增材制造监控设备因获取信息不全面而无法及时发现加工缺陷产生原因的问题。The purpose of the present invention is to provide an online real-time monitoring system for various monitoring equipment for metal additive manufacturing, which is intended to solve the problem that the existing monitoring equipment for metal additive manufacturing cannot find the cause of processing defects in time due to incomplete information obtained. .
本发明是这样实现的:The present invention is realized in this way:
本发明提供一种金属增材制造多种监测设备在线实时监控系统,包括高速相机检测模块、可见分光计检测模块、红外热像仪检测模块、抵近可见高光谱相机检测模块、干涉成像光谱仪检测模块、应力应变检测模块、激光超声检测模块、电子计算机断层扫描模块、激光诱导击穿光谱检测模块以及中央处理器,上述各检测模块均与所述中央处理器电连接;The invention provides an online real-time monitoring system for various monitoring equipment for metal additive manufacturing, including a high-speed camera detection module, a visible spectrometer detection module, an infrared thermal imager detection module, a near-visible hyperspectral camera detection module, and an interference imaging spectrometer detection module. a module, a stress-strain detection module, a laser ultrasonic detection module, an electronic computed tomography scanning module, a laser-induced breakdown spectroscopy detection module, and a central processing unit, each of which is electrically connected to the central processing unit;
所述高速相机检测模块用于对增材制造件的三维轮廓精度和熔池轮廓进行实时检测并反馈给中央处理器;所述可见分光计检测模块用于对激光的偏转角进行实时检测并反馈给中央处理器;所述红外热像仪检测模块用于对熔池温度进行实时检测并反馈给中央处理器;所述抵近可见高光谱相机检测模块用于对熔池、溅射以及周围环境的空间信息和光谱信息进行实时检测并反馈给中央处理器;所述干涉成像光谱仪检测模块用于利用干涉原理获得一系列随光程差变化的干涉图样,通过反演得到增材制造件的二维空间图像和一维光谱信息并反馈给中央处理器;所述应力应变检测模块用于利用应力应变传感器获得加工过程中增材制造件的应力应变数据并反馈给中央处理器;所述激光超声检测模块配合旋转式加工台用于对增材制造件的表面及近表面缺陷进行实时检测并反馈给中央处理器;所述电子计算机断层扫描模块配合旋转式加工台检测增材制造件的内部缺陷并反馈给中央处理器;所述激光诱导击穿光谱检测模块用于确定增材制造件物质成分及含量并反馈给中央处理器;所述中央处理器用于将上述各检测模块反馈的信息与其设定信息进行比较,发现加工误差和冶金缺陷后反馈给金属增材制造加工端,从而实现加工过程的实时调控。The high-speed camera detection module is used for real-time detection of the three-dimensional contour accuracy and molten pool profile of the additively manufactured parts and fed back to the central processing unit; the visible spectrometer detection module is used for real-time detection and feedback of the deflection angle of the laser to the central processing unit; the infrared thermal imager detection module is used to detect the temperature of the molten pool in real time and feed it back to the central processing unit; the near-visible hyperspectral camera detection module is used to detect the molten pool, sputtering and the surrounding environment The spatial information and spectral information are detected in real time and fed back to the central processing unit; the interferometric imaging spectrometer detection module is used to obtain a series of interference patterns that vary with the optical path difference by using the interference principle, and obtain the second part of the additively manufactured part through inversion. 3D space image and 1D spectral information are fed back to the central processing unit; the stress and strain detection module is used to obtain the stress and strain data of the additively manufactured part during processing by using the stress and strain sensor and feed it back to the central processing unit; the laser ultrasonic wave The detection module cooperates with the rotary processing table for real-time detection of surface and near-surface defects of the additively manufactured parts and feeds them back to the central processing unit; the electronic computed tomography scanning module cooperates with the rotary processing table to detect the internal defects of the additively manufactured parts and feedback it to the central processing unit; the laser-induced breakdown spectroscopy detection module is used to determine the material composition and content of the additively manufactured part and feed it back to the central processing unit; the central processing unit is used to combine the information fed back by the above detection modules with their settings. The processing error and metallurgical defects are found and then fed back to the metal additive manufacturing processing end, so as to realize the real-time control of the processing process.
进一步地,所述中央处理器还用于根据高速相机检测模块反馈的增材制造件的三维轮廓精度和熔池轮廓以及红外热像仪检测模块反馈的熔池温度信息形成加工过程的精度—温度关系,并与设定的精度—温度曲线进行比对,将比对结果反馈给金属增材制造加工端进而调节加工温度和激光移动速度至二者结合的最优值。Further, the central processing unit is also used to form the accuracy-temperature of the processing process according to the three-dimensional contour accuracy and molten pool contour of the additively manufactured part fed back by the high-speed camera detection module and the molten pool temperature information fed back by the infrared thermal imager detection module. The relationship is compared with the set accuracy-temperature curve, and the comparison result is fed back to the metal additive manufacturing processing end to adjust the processing temperature and laser moving speed to the optimal value of the combination of the two.
进一步地,所述中央处理器还用于根据高速相机检测模块反馈的增材制造件的三维轮廓精度和熔池轮廓、干涉成像光谱仪检测模块反馈的增材制造件的二维空间图像和一维光谱信息以及激光超声检测模块反馈的增材制造件的表面及近表面缺陷信息对增材制造件的表面瑕疵进行定位,将定位信息反馈给金属增材制造加工端。Further, the central processing unit is also used for the three-dimensional contour accuracy and molten pool contour of the additively manufactured part fed back by the high-speed camera detection module, and the two-dimensional spatial image and one-dimensional image of the additively manufactured part fed back by the interference imaging spectrometer detection module. The spectral information and the surface and near-surface defect information of the additive manufacturing part fed back by the laser ultrasonic inspection module locate the surface defects of the additive manufacturing part, and feed the positioning information to the metal additive manufacturing processing end.
进一步地,所述中央处理器还用于根据抵近可见高光谱相机检测模块反馈的熔池、溅射以及周围环境的空间信息和光谱信息以及干涉成像光谱仪检测模块反馈的增材制造件的二维空间图像和一维光谱信息进行成型成像之后得到增材制造件的完整的一维光谱、二维图像和三维图形。Further, the central processing unit is also used for the second part of the additively manufactured part according to the spatial information and spectral information of the molten pool, sputtering and surrounding environment fed back by the detection module of the near-visible hyperspectral camera, and the detection module of the interference imaging spectrometer. The complete one-dimensional spectrum, two-dimensional image and three-dimensional graphics of the additively manufactured part are obtained after molding and imaging with one-dimensional spatial image and one-dimensional spectral information.
进一步地,所述中央处理器将上述各检测模块采集到的多种物理量进行多尺度、多概率仿真,在虚拟空间中完成映射,进而建立数字孪生模型,通过模型产生对应于金属增材制造加工端的修改信息,并将修改信息实时反馈给金属增材制造加工端进行实时调控。Further, the central processing unit performs multi-scale and multi-probability simulation on the various physical quantities collected by the above-mentioned detection modules, completes the mapping in the virtual space, and then establishes a digital twin model, and generates a corresponding metal additive manufacturing process through the model. The modification information of the terminal, and the modification information is fed back to the metal additive manufacturing processing terminal in real time for real-time regulation.
进一步地,所述红外热像仪检测模块包括红外热像仪,所述红外热像仪置于金属增材质造腔体上方且其前方的部分腔体采用蓝宝石材质。Further, the infrared thermal imager detection module includes an infrared thermal imager, the infrared thermal imager is placed above the metal additively fabricated cavity, and a part of the cavity in front of the infrared thermal imager is made of sapphire material.
进一步地,所述可见分光计检测模块包括可见分光计,所述可见分光计置于金属增材质造腔体内。Further, the visible spectrometer detection module includes a visible spectrometer, and the visible spectrometer is placed in the metal additive manufacturing cavity.
进一步地,所述干涉成像光谱仪检测模块包括干涉成像光谱仪,所述干涉成像光谱仪置于金属增材质造腔体外一侧且其前方的部分腔体采用有机玻璃。Further, the interferometric imaging spectrometer detection module includes an interferometric imaging spectrometer, and the interferometric imaging spectrometer is placed on the outside of the metal additive manufacturing cavity and a part of the cavity in front of the interferometric imaging spectrometer is made of plexiglass.
进一步地,所述激光超声检测模块包括激光发射器和超声探测器,所述激光超声检测模块置于金属增材质造腔体外一侧且其前方的部分腔体采用Glass WindowsDK7材质。Further, the laser ultrasonic detection module includes a laser transmitter and an ultrasonic detector, and the laser ultrasonic detection module is placed on the outer side of the metal additively fabricated cavity, and part of the cavity in front of it is made of Glass WindowsDK7 material.
进一步地,所述激光超声检测模块前方的部分腔体内侧涂装抗反射涂层。Further, the inner side of part of the cavity in front of the laser ultrasonic detection module is coated with an anti-reflection coating.
进一步地,所述激光诱导击穿光谱检测模块包括脉冲激光器和光电转化器,所述激光诱导击穿光谱检测模块置于金属增材质造腔体外一侧且其前方的部分腔体采用GlassWindowsDK7材质。Further, the laser-induced breakdown spectroscopy detection module includes a pulsed laser and a photoelectric converter, and the laser-induced breakdown spectroscopy detection module is placed on the outside of the metal additively fabricated cavity and part of the cavity in front of it is made of GlassWindowsDK7 material.
进一步地,所述电子计算机断层扫描模块包括X射线发射器、X射线接收装置和成像系统,所述电子计算机断层扫描模块置于金属增材质造腔体外一侧且其前方的部分腔体采用有机玻璃。Further, the electronic computed tomography scanning module includes an X-ray transmitter, an X-ray receiving device and an imaging system, and the electronic computed tomography scanning module is placed on the outside of the metal additive manufacturing cavity and part of the cavity in front of it is made of organic materials. Glass.
进一步地,所述应力应变检测模块包括应力应变片,所述应力应变片贴合在基板以及增材制造件上。Further, the stress and strain detection module includes a stress and strain gauge, and the stress and strain gauge is attached to the substrate and the additively manufactured part.
与现有技术相比,本发明具有以下有益效果:Compared with the prior art, the present invention has the following beneficial effects:
本发明提供的这种金属增材制造多种监测设备在线实时监控系统,通过多种监测设备同时在线全方位收集金属增材制造加工过程中的各种信息,可以大大提高金属增材制造件在打印过程中的检测精度,最终提高成品件的质量,降低原料浪费降低成本;通过各个检测模块自动反馈缺陷信息,提高反馈的时效性,进而实现从金属增材制造加工处采集信息,中央处理器分析采集数据并将误差数据反馈至金属增材制造加工端的闭环控制,大幅度地节约了打印时间,提高了金属增材制造效率。The on-line real-time monitoring system for various monitoring equipment for metal additive manufacturing provided by the present invention can collect various information in the process of metal additive manufacturing in an all-round way simultaneously and online through various monitoring equipment, which can greatly improve the performance of metal additive manufacturing parts. The detection accuracy in the printing process will ultimately improve the quality of finished parts, reduce waste of raw materials and reduce costs; through each detection module automatically feedback defect information, improve the timeliness of feedback, and then realize the collection of information from the metal additive manufacturing processing center, the central processing unit The closed-loop control of analyzing the collected data and feeding the error data back to the processing end of metal additive manufacturing greatly saves printing time and improves the efficiency of metal additive manufacturing.
附图说明Description of drawings
图1为本发明实施例提供的金属增材制造多种监测设备在线实时监控系统工作示意图;FIG. 1 is a schematic working diagram of an online real-time monitoring system for multiple monitoring equipment for metal additive manufacturing provided by an embodiment of the present invention;
图2为本发明实施例提供的金属增材制造多种监测设备在线实时监控系统闭环控制流程图;FIG. 2 is a closed-loop control flow chart of an online real-time monitoring system for multiple monitoring equipment for metal additive manufacturing provided by an embodiment of the present invention;
图3为本发明实施例提供的金属增材制造系统及其多种监测设备在线实时监控系统结构图。FIG. 3 is a structural diagram of an on-line real-time monitoring system of a metal additive manufacturing system and various monitoring devices thereof provided by an embodiment of the present invention.
附图标记说明:1-旋转式加工台、2-激光器、3-可见分光计、4-干涉成像光谱仪、5-红外热像仪、6-高速工业相机、7-抵近可见高光谱相机、8-激光超声检测模块、9-GlassWindowsDK7材质部分腔体、10-高透玻璃部分腔体、11-蓝宝石材质部分腔体、12-有机玻璃部分腔体、13-激光诱导击穿光谱检测模块、14-电子计算机断层扫描模块、15-线缆、16-中央处理器、17-信息反馈模块、18-应力应变检测模块、19-X射线接收装置。Explanation of reference numerals: 1-rotary processing table, 2-laser, 3-visible spectrometer, 4-interference imaging spectrometer, 5-infrared thermal imager, 6-high-speed industrial camera, 7-proximity-visible hyperspectral camera, 8-Laser ultrasonic detection module, 9-GlassWindowsDK7 material part cavity, 10-High transparent glass part cavity, 11-Sapphire material part cavity, 12-Plexiglas part cavity, 13-Laser induced breakdown spectroscopy detection module, 14-electronic computed tomography scanning module, 15-cable, 16-central processing unit, 17-information feedback module, 18-stress and strain detection module, 19-X-ray receiving device.
具体实施方式Detailed ways
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其它实施例,都属于本发明保护的范围。The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.
如图1至图3所示,本发明实施例提供一种金属增材制造多种监测设备在线实时监控系统,包括高速相机检测模块、可见分光计检测模块、红外热像仪检测模块、抵近可见高光谱相机检测模块、干涉成像光谱仪检测模块、应力应变检测模块、激光超声检测模块、电子计算机断层扫描模块、激光诱导击穿光谱检测模块以及中央处理器,上述各检测模块均与所述中央处理器电连接。所述高速相机检测模块用于通过拍摄图像对增材制造件的三维轮廓精度和熔池轮廓进行实时检测并反馈给中央处理器,中央处理器通过图像处理算法将获取的增材制造件的三维轮廓精度和熔池平面缺陷与设定信息进行比较,发现误差后反馈给金属增材制造加工端进行修改,从而实现对增材制造件的三维轮廓和熔池轮廓进行调控;所述可见分光计检测模块用于对激光的偏转角进行实时检测并反馈给中央处理器,中央处理器通过比较算法将获取的激光的偏转角与设定值进行比较,发现误差后反馈给金属增材制造加工端进行修改,从而实现对激光偏转角进行实时调控;所述红外热像仪检测模块用于对熔池温度进行实时检测并反馈给中央处理器,中央处理器通过温度推算算法根据获取的熔池温度推算出激光强度,将推算出的激光强度与设定值进行比较,发现误差后反馈给金属增材制造加工端进行修改,从而实现对激光强度进行实时调控;所述抵近可见高光谱相机检测模块用于对熔池、溅射以及周围环境的空间信息和光谱信息进行实时检测并反馈给中央处理器,抵近可见高光谱相机检测模块既可以检测到被检测物体的外部品质,又可以利用高光谱技术检测熔池以及溅射的内部品质,做到内外兼修对金属增材制造加工过程中的熔池进行全方位监测,中央处理器通过比较算法将获取的空间和光谱信息与设定值进行比较,发现误差后反馈给金属增材制造加工端进行修改,从而实现对熔池品质进行实时调控;所述干涉成像光谱仪检测模块用于利用干涉原理获得一系列随光程差变化的干涉图样,通过反演得到增材制造件的二维空间图像和一维光谱信息并反馈给中央处理器,中央处理器通过比较算法将获取的增材制造件的二维空间图像和一维光谱信息与设定值进行比较,发现不同后反馈给金属增材制造加工端,从而对相关的加工过程进行实时调控;所述应力应变检测模块用于利用应力应变传感器获得加工过程中增材制造件的应力应变数据并反馈给中央处理器,中央处理器通过比较算法将获取的加工过程中增材制造件的应力应变数据与设定值进行比较,发现不同后反馈给金属增材制造加工端,从而对相关的加工过程进行实时调控;所述激光超声检测模块配合旋转式加工台用于对增材制造件的表面及近表面缺陷进行实时检测并反馈给中央处理器,中央处理器通过比较算法将获取的增材制造件的表面缺陷以及材料参数与设定值进行比较,发现误差后反馈给金属增材制造加工端进行修改,从而实现对增材制造件的表面及近表面缺陷近参数进行实时调控;所述电子计算机断层扫描模块配合旋转式加工台用于对增材制造件的内部缺陷和内部几何轮廓进行实时检测并反馈给中央处理器,中央处理器通过比较算法将获取的增材制造件的内部缺陷和内部几何轮廓与已有图片进行比较,发现误差后反馈给金属增材制造加工端进行修改,从而实现对可能出现的增材制造件的内部问题进行实时修正;所述激光诱导击穿光谱检测模块用于对增材制造件的物质成分及含量进行实时检测并反馈给中央处理器,中央处理器通过比较算法将获取的增材制造件的物质成分及含量与设定值进行比较,发现误差后反馈给金属增材制造加工端进行修改,从而实现对增材制造件的物质成分及含量参数进行实时调控。其中,中央处理器中的各算法可以采用python进行编写,也可以采用其他的计算机程序设计语言进行编写。金属增材制造加工端一般为金属3D打印机以及激光器,还可以包括其他控制设备。As shown in FIGS. 1 to 3 , an embodiment of the present invention provides an online real-time monitoring system for various monitoring equipment for metal additive manufacturing, including a high-speed camera detection module, a visible spectrometer detection module, an infrared thermal imager detection module, a proximity Visible hyperspectral camera detection module, interference imaging spectrometer detection module, stress-strain detection module, laser ultrasonic detection module, electronic computed tomography scanning module, laser-induced breakdown spectroscopy detection module and central processing unit, the above detection modules are all related to the central processing unit. The processor is electrically connected. The high-speed camera detection module is used for real-time detection of the three-dimensional contour accuracy and molten pool contour of the additively manufactured part by capturing images and feeding it back to the central processing unit. The contour accuracy and weld pool plane defects are compared with the setting information, and after errors are found, they are fed back to the metal additive manufacturing processing end for modification, so as to realize the regulation of the three-dimensional contour and weld pool contour of the additively manufactured part; the visible spectrometer The detection module is used to detect the deflection angle of the laser in real time and feed it back to the central processing unit. The central processing unit compares the acquired deflection angle of the laser with the set value through a comparison algorithm, and feeds back to the metal additive manufacturing processing end after finding errors. Modification is made to realize real-time regulation of the laser deflection angle; the infrared thermal imager detection module is used to detect the temperature of the molten pool in real time and feed it back to the central processing unit. The laser intensity is calculated, the calculated laser intensity is compared with the set value, and the error is found and fed back to the metal additive manufacturing processing end for modification, so as to realize real-time control of the laser intensity; the near-visible hyperspectral camera detects The module is used to detect the spatial information and spectral information of the molten pool, sputtering and surrounding environment in real time and feed it back to the central processing unit. The near-visible hyperspectral camera detection module can not only detect the external quality of the detected object, but also use the The hyperspectral technology detects the internal quality of the molten pool and sputtering, so that both inside and outside can be used to monitor the molten pool in the metal additive manufacturing process in an all-round way. The central processing unit compares the obtained spatial and spectral information with the settings. After comparing the values, the error is found and fed back to the metal additive manufacturing processing end for modification, so as to realize real-time control of the quality of the molten pool; the interference imaging spectrometer detection module is used to obtain a series of interferences that vary with the optical path difference by using the interference principle. Pattern, obtain the two-dimensional spatial image and one-dimensional spectral information of the additively manufactured part through inversion and feed it back to the central processing unit, and the central processing unit compares the acquired two-dimensional spatial image and one-dimensional spectral information of the additively manufactured part Compared with the set value, it is found that the difference is fed back to the metal additive manufacturing processing end, so that the relevant processing process can be adjusted in real time; the stress and strain detection module is used to obtain the information of the additive manufacturing part in the processing process by using the stress and strain sensor. The stress and strain data are fed back to the central processing unit. The central processing unit compares the acquired stress and strain data of the additively manufactured part with the set value through the comparison algorithm, and then feeds back to the metal additive manufacturing processing end after finding the difference. Real-time control of the relevant processing process; the laser ultrasonic detection module cooperates with the rotary processing table to detect the surface and near-surface defects of the additively manufactured parts in real time and feed it back to the central processing unit. The acquired surface defects and material parameters of the additively manufactured parts are compared with the set values, and after the errors are found, they are fed back to the metal additive manufacturing processing end for modification, so as to realize the real-time monitoring of the surface and near-surface defects of the additively manufactured parts. regulation; the electronic The computed tomography scanning module cooperates with the rotary processing table for real-time detection of the internal defects and internal geometric contours of the additively manufactured parts and feeds them back to the central processing unit. The internal geometric contour is compared with the existing pictures, and after errors are found, it is fed back to the metal additive manufacturing processing end for modification, so as to realize real-time correction of possible internal problems of the additively manufactured parts; the laser-induced breakdown spectroscopy detection module It is used to detect the material composition and content of the additively manufactured parts in real time and feed it back to the central processing unit. Feedback to the metal additive manufacturing processing end for modification, so as to realize real-time regulation of the material composition and content parameters of the additively manufactured parts. Among them, each algorithm in the central processing unit can be written in python, and can also be written in other computer programming languages. The processing end of metal additive manufacturing is generally metal 3D printers and lasers, and can also include other control equipment.
本发明实施例提供的这种金属增材制造多种监测设备在线实时监控系统,通过多种监测设备同时在线全方位收集金属增材制造加工过程中的各种信息,可以大大提高金属增材制造件在打印过程中的检测精度,最终提高成品件的良品率,降低原料浪费降低成本;通过各个检测模块自动反馈缺陷信息,提高反馈的时效性,进而实现从金属增材制造加工处采集信息,中央处理器分析采集数据并将误差数据反馈至金属增材制造加工端的闭环控制,大幅度地节约了打印时间,提升了金属增材制造效率。The online real-time monitoring system for various monitoring equipment for metal additive manufacturing provided by the embodiment of the present invention, through the simultaneous online and omni-directional collection of various information in the process of metal additive manufacturing through various monitoring equipment, can greatly improve the metal additive manufacturing process. The detection accuracy of the parts in the printing process will ultimately improve the yield of the finished parts, reduce the waste of raw materials and reduce the cost; automatically feedback defect information through each detection module, improve the timeliness of the feedback, and then realize the collection of information from the metal additive manufacturing process. The central processor analyzes the collected data and feeds back the error data to the closed-loop control of the metal additive manufacturing processing end, which greatly saves printing time and improves the efficiency of metal additive manufacturing.
优选地,所述中央处理器还用于根据高速相机检测模块反馈的增材制造件的三维轮廓精度和熔池轮廓以及红外热像仪检测模块反馈的熔池温度信息形成加工过程的精度—温度关系,并与设定的精度—温度曲线进行比对,将比对结果反馈给金属增材制造加工端进而调节加工温度和激光移动速度至二者结合的最优值。Preferably, the central processing unit is further configured to form the accuracy-temperature of the processing process according to the three-dimensional contour accuracy and molten pool contour of the additively manufactured part fed back by the high-speed camera detection module and the molten pool temperature information fed back by the infrared thermal imager detection module The relationship is compared with the set accuracy-temperature curve, and the comparison result is fed back to the metal additive manufacturing processing end to adjust the processing temperature and laser moving speed to the optimal value of the combination of the two.
优选地,所述中央处理器还用于根据高速相机检测模块反馈的增材制造件的三维轮廓精度和熔池轮廓、干涉成像光谱仪检测模块反馈的增材制造件的二维空间图像和一维光谱信息以及激光超声检测模块反馈的增材制造件的表面及近表面缺陷信息对增材制造件的表面瑕疵进行定位,将定位信息反馈给金属增材制造加工端,以在下次加工时在瑕疵部位减慢加工速度,提高加工精度。Preferably, the central processing unit is also used for the three-dimensional contour accuracy and molten pool contour of the additively manufactured part fed back by the high-speed camera detection module, and the two-dimensional spatial image and one-dimensional image of the additively manufactured part fed back by the interference imaging spectrometer detection module The spectral information and the surface and near-surface defect information of the additive manufacturing part fed back by the laser ultrasonic inspection module locate the surface defects of the additive manufacturing part, and feed back the positioning information to the metal additive manufacturing processing end, so that the defects can be detected in the next processing. The part slows down the processing speed and improves the processing accuracy.
优选地,所述中央处理器还用于根据抵近可见高光谱相机检测模块反馈的熔池、溅射以及周围环境的空间信息和光谱信息以及干涉成像光谱仪检测模块反馈的增材制造件的二维空间图像和一维光谱信息进行成型成像之后得到增材制造件的完整的一维光谱、二维图像和三维图形,从一维到三维更加完整的体现增材制造件特征,方便对加工过程进行观察和研究。Preferably, the central processing unit is also used for the second part of the additively manufactured parts according to the spatial information and spectral information of the molten pool, sputtering and surrounding environment fed back by the detection module of the near-visible hyperspectral camera and the detection module of the interference imaging spectrometer. The complete one-dimensional spectrum, two-dimensional image and three-dimensional graphics of the additively manufactured part are obtained after molding and imaging of the one-dimensional space image and one-dimensional spectral information, which more completely reflects the characteristics of the additively manufactured part from one-dimensional to three-dimensional, which is convenient for the processing process. Make observations and research.
更为优选地,所述中央处理器将上述各检测模块采集到的多种物理量进行多尺度、多概率仿真,在虚拟空间中完成映射,进而建立数字孪生模型(Digital Twin),通过模型产生对应于金属增材制造加工端的修改信息,并将修改信息实时反馈给金属增材制造加工端进行实时调控。修改信息具体可以为激光束的轨迹调节量和移动速度调节量、激光强度调节量、激光的偏转角调节量等。如图2所示,通过各检测模块、中央处理器以及金属3d打印机的相互配合,最终实现“打印-监测-反馈-修改-打印”的闭环控制,实现对打印过程的全方位在线实时监测和调节。More preferably, the central processing unit performs multi-scale and multi-probability simulation on the various physical quantities collected by the above-mentioned detection modules, completes the mapping in the virtual space, and then establishes a digital twin model (Digital Twin), and generates a corresponding model through the model. The modification information on the metal additive manufacturing processing end, and the modification information is fed back to the metal additive manufacturing processing terminal in real time for real-time regulation. The modification information may specifically be the adjustment amount of the trajectory of the laser beam and the adjustment amount of the moving speed, the adjustment amount of the laser intensity, the adjustment amount of the deflection angle of the laser, and the like. As shown in Figure 2, through the mutual cooperation of each detection module, central processing unit and metal 3D printer, the closed-loop control of "printing-monitoring-feedback-modification-printing" is finally realized, and the all-round online real-time monitoring and control of the printing process is realized. adjust.
如图3所示为金属增材制造系统及其多种监测设备在线实时监控系统的示意图。其中,金属增材制造系统包括金属增材制造腔体以及置于腔体内的金属3d打印机1以及激光器2,除下述特别说明的部分之外,腔体其余部分10采用普通高透玻璃。所述高速相机检测模块包括高速工业相机6,高速工业相机6置于金属增材质造腔体外一侧。所述红外热像仪检测模块包括红外热像仪5,所述红外热像仪5置于金属增材质造腔体上方,由于普通玻璃会对红外线进行反射阻隔,故在红外热像仪5前不宜采用普通玻璃,本发明实施例红外热像仪5前方的部分腔体11采用蓝宝石材质,蓝宝石(Al2O3)从近紫外线到中红外都有十分优良的透光性,与此同时蓝宝石具有很高的机械强度,完全可以做到支撑金属增材制造的外部腔体,高透光性可以让红外射线顺利通过,有效降低光学误差导致的测量误差,使红外热像仪5更加准确地测算数据。所述可见分光计检测模块包括可见分光计3,所述可见分光计3置于金属增材质造腔体内。所述抵近可见高光谱相机检测模块包括抵近可见高光谱相机7,所述抵近可见高光谱相机7置于金属增材质造腔体上方。所述干涉成像光谱仪4检测模块包括干涉成像光谱仪4,所述干涉成像光谱仪4置于金属增材质造腔体外一侧,由于普通玻璃会对光的干涉过程产生较大影响,如果在干涉成像光谱仪4前方采用普通玻璃会使测算结果产生较大误差,本发明实施例干涉成像光谱仪4前方的部分腔体12采用有机玻璃,有机玻璃(PMMA)光学性能使得它对光的干涉影响较小,并且它的化学稳定性,力学性能和耐候性都十分优良,可以把信息采集过程中的光学误差降到最小。所述激光超声检测模块8包括激光发射器和超声探测器,所述激光超声检测模块8置于金属增材质造腔体外一侧,由于激光超声检测模块8的激光脉冲以及与工件接触之后所激发的超声波对腔体材质的透过性要求较高,本发明实施例激光超声检测模块8前方的部分腔体9采用Glass WindowsDK7材质,使用该材质可以有效降低激光反射导致的误差。由于激光会对人眼产生一定的伤害,本优选实施例中在激光超声检测模块8前方的部分腔体内侧涂装抗反射涂层,保护检测人员的眼睛。所述激光诱导击穿光谱检测模块13包括脉冲激光器和光电转化器,所述激光诱导击穿光谱检测模块置于金属增材质造腔体外一侧且其前方的部分腔体采用GlassWindowsDK7材质。所述电子计算机断层扫描模块14包括X射线发射器、X射线接收装置和成像系统,所述电子计算机断层扫描模块14置于金属增材质造腔体外一侧且其前方的部分腔体采用有机玻璃,X射线发射器发射X射线至X射线接收装置19。所述应力应变检测模块18包括应力应变片,所述应力应变片贴合在基板以及增材制造件上,从而对加工过程中增材制造件的应力应变数据。本发明实施例根据不同监测设备的信息采集特性,在不同设备前采用不一样的腔体材质,有效降低光学、热能学等误差,进而提升检测精度。Figure 3 is a schematic diagram of the online real-time monitoring system of the metal additive manufacturing system and its various monitoring equipment. The metal additive manufacturing system includes a metal additive manufacturing cavity, a
上述各检测模块还包括将检测仪器连接至中央处理器14的线缆以及固定检测仪器的固定件。该监控系统还包括信息反馈模块17,信息反馈模块17通过线缆15与中央处理器16连接,上述各检测模块采集的信息通过线缆15传输至中央处理器16,中央处理器16信息处理完毕后输送至信息反馈模块17再反馈至金属3d打印机1实现一个闭环控制,进而提高打印精度,提高打印质量,还可以储存大量错误信息为后一步的人工智能学习纠错做好准备。Each of the above-mentioned detection modules further includes a cable for connecting the detection instrument to the
金属增材制造过程中由于激光加工处于高温高亮环境,各监测系统主要通过光学原理检测,为避免激光热源对各监测系统的影响,所选加工热源与各监测系统波长不同的红外激光,在进行电子计算机断层检测、激光超声检测、红外热像仪检测、以及使用激光诱导击穿光谱检测等无解耦方式时,可通过适当延迟测量时段,避开熔池以减少干扰。为避免热源对监测的影响,对于使用干涉成像光谱仪进行三维轮廓检测时,通过采用单波长(460nm)蓝光作为投影光源,安装对应波段滤光片进行解耦;对于熔池红外特征检测,通过同轴监测设计和窄带通滤波系统方式进行解耦;对于抵近可见高光谱检测,通过窄带通滤波系统方式进行解耦。从而保证各监测系统获取精确信息且互不干扰。In the process of metal additive manufacturing, since the laser processing is in a high-temperature and high-brightness environment, each monitoring system is mainly detected by the optical principle. When performing electronic computed tomography detection, laser ultrasonic detection, infrared thermal imaging detection, and laser-induced breakdown spectroscopy detection without decoupling, the molten pool can be avoided by appropriately delaying the measurement period to reduce interference. In order to avoid the influence of the heat source on the monitoring, when using the interference imaging spectrometer for three-dimensional contour detection, the single-wavelength (460nm) blue light is used as the projection light source, and the corresponding band filter is installed for decoupling; for the infrared feature detection of the molten pool, the same The shaft monitoring design and the narrow band-pass filter system are used for decoupling; for near-visible hyperspectral detection, the decoupling is carried out by the narrow band-pass filter system. This ensures that each monitoring system obtains accurate information without interfering with each other.
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。The above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the scope of the present invention. within the scope of protection.
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